Personalized interface for torch system and method

ABSTRACT

There is provided a system and method for quick identification and selection of torch processes based on a profile scheme. In an illustrated embodiment, a profile selectable via a one-click process may define operational parameters for one or more torch processes. Multiple profiles may be identified by corresponding labels that are visible on the face of the system. Furthermore, in an illustrated embodiment, the profiles and associated torch processes may be automatically stored in the system upon user configuration of the operational parameters. For example, in one embodiment, the user may select a profile and configure a welding process. Upon changing an operational parameter, it may be automatically saved to the selected profile and process. Reselection of that profile may recall the last used process and its associated parameters. The operational parameters of other configured processes may then be retrieved by selecting the desired process within the selected profile.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Non-Provisional patent application of U.S.Provisional Patent Application No. 61/014,670, entitled “PERSONALIZEDINTERFACE FOR TORCH SYSTEM AND METHOD”, filed Dec. 18, 2007, which isherein incorporated by reference in its entirety.

BACKGROUND

The invention relates generally to a torch system and control of variousfeatures according to user preferences.

Torch systems generally support different types of processes, includingmetal inert gas (MIG) welding, tungsten inert gas (TIG) welding, stickwelding, air carbon arc cutting (CAC-A), plasma arc cutting, etc.Multi-process torch equipment may provide control for several processesin a single unit. A multi-process torch system may employ a relativelysophisticated user interface with controls, displays, etc. to setup andcontrol the various processes for which it is designed. Depending on thespecific application, an operator may be required to switch betweenwelding and/or cutting processes on a regular basis to properly completea job. Switching between processes may require the operator to selectthe new process to be used and to change the equipment settings toachieve optimal performance. This process is time consuming, impactsproductivity, and requires the operator to remember the specificsettings for each particular process. Furthermore, a single torch systemis often used by multiple operators, and each operator may have personalpreferences for a given type of process. Each operator may need toadjust the system before every use, which can become very timeconsuming.

BRIEF DESCRIPTION

A torch system, in one embodiment, may include a personalized interfacehaving multiple selectors each corresponding to a configurable profile.Each selector may adjust operational parameters of the torch system uponselection. In another embodiment, a torch system may include aprogrammable controller having a personalized user interface. Thepersonalized user interface may have at least one quick selector forrecalling the operational parameters of a torch process. A torch system,in another embodiment, may include tangible, machine-readable mediahaving code executable to save operational parameters for multipleprofiles automatically upon user selection of the operational parametersfor each profile and/or code executable to recall the operationalparameters for each profile to configure the torch system based on aone-click user selection of each profile. In a further embodiment, amethod includes automatically saving a user profile to a profileselector based on one or more selections of operational parameters of atorch system via controls separate from the profile selector. A furtherembodiment of a torch system may include a personalized interface havingmultiple customizable profiles, each having operational parameters forthe torch system, wherein a desired customizable profile is selectablewithout scrolling through a list of the customizable profiles.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of a torch system having a personalizedinterface in accordance with exemplary embodiments of the presentinvention;

FIGS. 2-4 are front views of exemplary personalized interfaces for usewith the torch system of FIG. 1 in accordance with embodiments of thepresent invention;

FIG. 5 is an organizational chart for a plurality of profiles andprocesses in accordance with the exemplary embodiments illustrated inFIGS. 2-4;

FIGS. 6-7 are front views of exemplary personalized interfaces for usewith the torch system of FIG. 1 in accordance with further embodimentsof the present invention;

FIG. 8 is an organizational chart for a plurality of profiles andprocesses in accordance with the exemplary embodiments illustrated inFIGS. 7-8; and

FIG. 9 is a block diagram of a process control board for use in thetorch system of FIG. 1 in accordance with embodiments of the presentinvention.

DETAILED DESCRIPTION

One or more specific embodiments of the present invention will bedescribed below. In an effort to provide a concise description of theseembodiments, not all features of an actual implementation are describedin the specification. It should be appreciated that in the developmentof any such actual implementation, as in any engineering or designproject, numerous implementation-specific decisions must be made toachieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

When introducing elements of various embodiments of the presentinvention, the articles “a,” “an,” “the,” and “said” are intended tomean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.Moreover, the use of “top,” “bottom,” “above,” “below,” and variationsof these terms is made for convenience, but does not require anyparticular orientation of the components. Finally, in the illustratedembodiments, features may be referred to as “selectors,” “buttons,”“switches,” or “knobs,” however these elements are not intended to belimited to the specific terminology used. That is, a “button” mayinclude, for example, a push-button, a toggle switch, a knob, or anysimilar device. Likewise, a “switch” is not limited to a single type ofswitch, such as a toggle, but may include a push-button or a knob, amongother devices. A “knob” may be, for example, a quadrature encoder, adial, a rotary switch, or a similar device.

A “quick selector,” as the term is used herein, may include any devicethat enables quick selection or deselection of an option. For example, abutton may be considered a quick selector because an option may beselected or deselected merely by depression of the button. Likewise, aswitch or a knob may be considered a quick selector. A scrolling device,on the other hand, would not be considered a quick selector as such adevice requires scrolling through a list to select or deselect anoption. Similarly, multi-step selection devices are not quick selectors.

FIG. 1 illustrates a multi-process torch system 10 in accordance with anembodiment of the present invention. The multi-process torch system 10may be configured to perform multiple processes, such as, for example,stick welding, flux cored arc welding (FCAW), gas metal arc welding(GMAW), shielded metal arc welding (SMAW), gas tungsten arc welding(GTAW), metal inert gas (MIG) welding, pulsed MIG welding, tungsteninert gas (TIG) welding, pulsed TIG welding, spot welding, resistancespot welding (RSW), submerged arc welding (SAW), regulated metaldeposition (RMD), air carbon arc cutting (CAC-A), plasma arc cutting,induction heating, power generation, wire feeding, or a combinationthereof.

The system 10 generally includes a power/control unit 12 having a powersource 14 and a controller 16; right and left torches or guns 18 and 20,respectively; and a shielding gas source 22. The power/control unit 12may be coupled to a wire feeder 24 configured to control the wire supplyto the first and second guns 18 and 20. The controller 16 may include apower source interface 26 and a process control board (not shown). Thepower source interface 26 includes a process interface 28 for inputtingoperational parameters to the process control board and a profileinterface 30 for selecting a desired profile. The process control boardincludes hardware and circuitry for storing programs (e.g., code onmemory) to operate the torch system 10. Furthermore, the wire feeder 24may include a wire feeder interface 32 coupled to the controller 16 suchthat operational parameters may be input to the process control boardvia the wire feeder interface 32. The power source interface 26 and thewire feeder interface 32 may control the same or different configurationsettings.

An exemplary embodiment of the power source interface 26 with uniquepersonalization control features is illustrated in FIG. 2. The powersource interface 26 may include controls for multiple welding, cutting,or heating processes. In the illustrated embodiment, the power sourceinterface 26 includes a plurality of profiles which may be selected bychoosing a profile selector 36. Each profile selector 36 has an adjacentdisplay area 38 for labeling the profile. For example, each profile maybe assigned to a different user, and the display areas 38 may list theusers' names. In another example, each profile may be assigned to atorch process, and the display areas 38 may list the processes. Thedisplay areas 38 may include white boards or ceramic labels on whichusers may write with a pen, grease pencil, marker, etc. In anotherembodiment, the display areas 38 may enable application of stickers ormagnets to the power source interface 26. In a further embodiment, thedisplay areas 38 may include digital displays, such as an LCD or similarscreen. In this embodiment, labels may be programmed into the powersource interface 26 for display on the display areas 38. A lightintegral with or adjacent to each profile selector 36 may indicate whichprofile is selected. The light may be integral with the profile numberssuch that the selected profile number lights up while the profile isselected. If the display area 38 is a display, the display may indicatewhich profile is selected by lighting up or alerting the user in anothermanner.

Each profile may correspond to one or more sets of operationalparameters for the torch system 10 (FIG. 1). For example, each profilemay correspond to a type of process, such as those described above. Auser may utilize controls independent from the profile selectors 36, asdescribed below, to set the operational parameters for each process andthen simply choose one of the profile selectors 36 to recall the savedoperational parameters for that profile. In another embodiment, eachprofile may be associated with a particular user, and the operationalparameters for multiple processes may be designated within the user'sprofile. That is, operational parameters for multiple processes, such asthose described above, may be saved to each profile. The desired userprofile may be recalled by selecting one of the profile selectors 36.The desired process may then be selected, as described below, and theuser's saved operational parameters for that process are recalled. Inany embodiment, selection of the desired profile selector 36automatically recalls operational parameters associated with theselected profile without the need to change other settings on the torchsystem 10. Additionally, the torch system 10 may be set to a defaultprofile and process upon first use, and each profile may likewise havedefault settings which can be adjusted by the user, as described below.

The illustrated exemplary power source interface 26 includes controlsettings for stick and TIG welding processes. A stick button 40 mayinitiate the stick welding process. The power source interface 26 mayinclude indicators to notify the user which settings are selected. Forexample, selection of the stick button 40 may light up the “STICK” labelor the button 40. An electrode switch 42 allows the user to selectbetween multiple possible electrodes to use in the stick weldingprocess. For example, the user may select between an E6010 and an E7018electrode, depending on the process parameters. Other electrode typesmay be offered as options in addition to, or instead of, the E6010 andE7018 electrodes. The electrode switch 42 may be a toggle switch, andthe selected electrode may be the one toward which the toggle is biased.In another embodiment, the electrode switch 42 may be a push button, andthe label for the selected electrode may light up to indicate theselection. Finally, an amperage knob 44 enables the user to adjust theamperage supplied to the torch (e.g., welding gun) in the stick weldingprocess. The amperage may be displayed on a display 46, such as, forexample, an LED or a seven-segment display. As described in more detailbelow, after the user selects one of the profile selectors 36 andadjusts the settings for the stick welding process, the selectedsettings may be automatically saved to the selected profile. That is,the user may return at a later time and select the previously-usedprofile to enable the configured settings. In another embodiment, theuser may adjust the settings for the stick welding process then save thesettings to a particular profile. For example, the profile selector 36corresponding to the desired profile may be depressed and held forseveral seconds to save the settings to that profile.

In addition to the stick welding process, the exemplary power sourceinterface 26 includes control settings for a TIG welding process. Asingle profile may store several processes, including both stick weldingparameters and TIG welding parameters. Parameters for additionalprocesses may be stored in each profile and accessed via additionalbuttons. For example, a TIG button 48 may initiate the TIG weldingprocess. As described above, selection of the TIG button 48 may light upthe “TIG” label or the button 48. Parameters for both stick welding andTIG welding may be stored in a given profile and recalled upondepression of the stick button 40 or the TIG button 48, depending on thedesired process. A start switch 50 enables the user to select whether touse a high frequency start method or a lift arc start method. The chosenstart method may be indicated by a toggle switch or a lit label. Theamperage knob 44 may be utilized to adjust amperage for the TIG weldingprocess in addition to the stick welding process. Adjusting the amperageknob 44 changes the amperage setting only for the selected process. Thatis, if the TIG button 48 is depressed, rotating the amperage knob 44adjusts only the amperage setting for the TIG welding process; theamperage setting for the stick welding process is not affected.

FIG. 3 illustrates another embodiment of the power source interface 26with unique personalization control features. In the illustratedembodiment, additional controls are provided to enable programming ofadditional welding process parameters for each profile. Specifically,the illustrated interface 26 includes all features of the interface 26(FIG. 2) along with many more user selections related to material, wiresize, gas, and so forth. As with the buttons described above, selectionof the operating parameters may be indicated by the position of a toggleor knob, or by the chosen option lighting up.

For each welding process, a base material for creating a weld, such ascarbon steel or stainless steel in the illustrated embodiment, may bedesignated using a base material switch 54. A wire size switch 56enables the user to specify the diameter (e.g., 0.035 or 0.045 inches)of the wire used in the welding process. For a MIG welding process, aMIG type switch 58 may be utilized to select the desired MIG weldingprocess. For example, the user may designate a standard MIG process, aregulated metal deposition (RMD) process, or a pulsed MIG process viathe switch 58.

In addition, a gas selection button 60 may enable the user to select ashielding gas for the MIG welding process. The gas selection button 60may, for example, be pressed until the desired gas is illuminated on anadjacent display chart 62. The gas selection may be limited by the basematerial and MIG type selections, as indicated in the illustratedembodiment. For example, if the user has chosen carbon as the basematerial (switch 54) and pulse as the MIG type (switch 58), the gasselection may be limited to C8-C15 (i.e., a mixture of argon and carbondioxide containing approximately 8-15% CO₂) as this is the only optionavailable in the Carbon Steel-Pulse column in display chart 62. On theother hand, if the user has chosen stainless steel as the base material(switch 54) and RMD as the MIG type (switch 58), the gas selection mayinclude C2 (i.e., a mixture of argon and carbon dioxide containingapproximately 2% CO₂), 98/2 Ox (i.e., a mixture containing approximately98% argon and 2% oxygen), TriH (i.e., a mixture containing approximately90% helium, 7.5% argon, and 2.5% carbon dioxide), or others as indicatedin the Stainless-MIG/RMD column. Selection of “others” may change thedisplayed options if more options are available than fit on the display62. It should be understood that any appropriate gases may be utilizedin the present system, and the display chart 62 may be updatedaccordingly.

Additionally, if a fixed torch is utilized in the designated weldingprocess, the user may indicate this by depressing a fixed torch button64. Finally, a trigger select button 66 may enable or disable theability of the user to change profiles by clicking a trigger on thetorch or gun.

Turning to FIG. 4, an exemplary embodiment of the wire feeder interface32 with unique personalization control features is illustrated. The wirefeeder interface 32, like the power source interface 26, may includecontrol settings for various processes (e.g., welding) using a wire. Inthe illustrated embodiment, a left gun button 70 and a right gun button72 may be utilized to select the desired gun 18 or 20, respectively. Asdescribed above, the user may determine whether buttons on the wirefeeder interface 32 are selected based on the position of a toggleswitch, a lit label, or a similar indicator. For example, where a buttonhas only one selection, as with the left and right gun buttons 70 and72, the buttons 70 and 72 may light up upon selection. For each gun, awelding process may be selected using process selection buttons 74 and76. For example, the process selection button 74 may be depressed ortoggled to select between a MIG welding process and a flux cored arcwelding (FCAW) process using the left gun 18. Similarly, the processselection button 76 may enable selection of a MIG welding process or aFCAW process using the right gun 20. Within each welding process,parameters may be set utilizing a voltage knob 78 and a wire feed speedknob 80. The selected voltage and wire feed speed are displayed ondisplays 82 and 84 adjacent to the knobs 78 and 80, respectively. Thedisplays 82 and 84 may be, for example, LCDs or seven-segment displays.A trigger hold button 88 may enable the user to weld for an extendedperiod of time without holding down the welding gun trigger.

In addition, a profile selection button 90 may be disposed on the wirefeeder interface 32 to enable the user to easily switch between profileswithout returning to the power/control unit 12 (FIG. 1). This feature isuseful when the power source 14 is located remotely from the wire feeder24. In one embodiment, the label for the chosen profile may be lit toindicate which profile is selected. In another embodiment, the profileselection button 90 may be a knob with an indicator pointing at theselected profile. Other indicators of profile selection may be used aswell. Additionally, a jog button 92 may be depressed to thread wirethrough the welding gun 18 or 20 without activating the weld process.Similarly, a purge button 94 may be depressed to purge shielding gasfrom the gun 18 or 20 without activating the welding process.

FIG. 5 is a flow chart illustrating an exemplary profile hierarchy 112that may be associated with the profile selectors 36 and 90 of theexemplary interfaces 26 and 32 illustrated in FIGS. 2-4. The illustratedembodiments include only four profiles, although an unlimited number ofprofiles may be utilized. In the illustrated embodiments, a user mayselect a user/process profile 114 by selecting one of the profileselectors 36 (FIG. 2 or 3) or depressing the profile selection button 90(FIG. 4) until the desired profile number is selected. The first timethe profile 114 is selected, default welding parameters areautomatically recalled. For example, the default settings for profileone may be a stick welding process utilizing an E6010 electrode at 85amps. The user may change the settings for the stick welding process orselect a different process. In this example, any changes made whileprofile one is selected are saved such that they may be recalled at alater time. A different user/process profile 114 may be selected, andupon returning to profile one the last utilized process and settingswill automatically be recalled. In addition, changes to any otherprocesses within profile one may be recalled by selecting the desiredprocess.

The user may select the desired profile 114 via the profile selectors 36and 90. By programming operational parameters into the profiles 114, thedesired parameters associated with each profile 114 may be recalled witha single push of a button (e.g., the profile selectors 36 and 90)without the trouble of manually adjusting each and every control on thesystem 10. For example, the profile 114 may correspond to a specificuser and/or to a specific process. Within the profile 114, the user mayselect between a stick process 116, a TIG process 118, a left gunprocess 120, or a right gun process 122. The stick process 116 mayinclude selection of either an E6010 electrode 124 or an E7018 electrode126. For each electrode 124 and 126, amperage 128 and 130 may be set,respectively. Likewise, in the TIG process, an amperage 132 may beinput, and a high frequency start 134 or a lift-arc start 136 may beselected. For the left gun 120, a MIG process 138 or a FCAW process 140may be selected. A voltage 142 and a wire feed speed 144 may be adjustedfor the MIG process 138, and a trigger hold option 146 may be selected.Likewise, for the FCAW process 140, a voltage 148 and a wire feed speed150 may be input, and a trigger hold option 152 may be selected. As withthe left gun process 120, the right gun process 122 may be a MIG process154 or a FCAW process 156. For each of the MIG process 154 and the FCAWprocess 156, the user may select a voltage 158 and 160, a wire speedfeed 162 and 164, and a trigger hold option 166 and 168, respectively.Other settings and processes may be specified based on the processesavailable on the given welding system 10. If multiple processes aredefined in the desired profile 114, the user may also press a button(e.g., stick button 40, TIG button 48, left gun button 70, right gunbutton 72, etc.) to recall the operational parameters associated withthe desired process 116, 118, 130, or 122 in the desired profile 114.

Furthermore, it may be desirable to set each profile 114 to a specificprocess having user-independent settings. For example, profile one maybe set to automatically recall settings for the stick welding process116, while profile two may automatically initialize the TIG weldingprocess 118. Every user of the welding system 10 may then utilize thesame process settings. This feature enables one-touch switching betweenprocesses by assigning a different process or different settings to eachprofile 114. One-touch recall of different process settings may beespecially useful where certain welding processes are commonly used onthe welding system 10 and the settings for each process do not changefrom user to user. The process specified for each profile 114 may belabeled on the display area 38 (FIGS. 2-3) so that the user can easilyidentify which profile selector 36 corresponds to which profile 114.

In addition, if the welding system 10 is used by different welders whohave preferred settings for each welding process, each profile 114 maybe assigned to a different user. The users' names may be displayed onthe display areas 38 (FIGS. 2-3) adjacent to the profile selectors 36.The user may then select his or her name and adjust the availablewelding process to preference. In this scenario, the user may press thedesired profile selector 36 to return to the last welding processutilized by that user. If desired, a different process may then beselected within that user's profile 114. In another embodiment, theprofile selectors 36 may be pressed multiple times to step through theprocesses associated with the user. That is, the user may press theprofile selector 36 next to his name once to recall his profile 114 andhis first designated process (or last used process). Pressing the sameprofile selector 36 again may switch the system 10 to the next processassociated with the profile 114. In this manner, the user may select hisprofile selector 36 until the desired process is activated, as indicatedby the same indicators described above which would otherwise indicateselection of a given process.

Another exemplary embodiment of the power source interface 26 withunique personalization control features is illustrated in FIG. 6. Manyof the controls described in FIG. 3 are also included in the presentembodiment, wherein like element numbers indicate like features. Forexample, to enable programming of welding process parameters for eachprofile, the illustrated interface 26 includes user selections relatedto continuous wire process type, material, wire, gas, and so forth. Acover 170 may be attached to the power source interface 26 to protectand/or hide some or all of the selection buttons when closed. In theillustrated embodiment, the cover 170 is rotatably coupled to theinterface 26, e.g., via a hinge or pivot joints 171. As with the buttonsdescribed above, selection of the operating parameters may be indicatedby the position of a toggle or knob, or by the chosen option lightingup. As described above, the buttons, selectors, knobs, and so forthdescribed herein may be push-buttons, toggles, knobs, quadratureencoders, dials, rotary switches, or any similar device. In addition,the profile selector 36 operates as described above.

The power source interface 26 illustrated in FIG. 6 may enable selectionof operating parameters for stick, TIG, and MIG welding processes. Forexample, the stick button 40 initiates programming of a stick weldingprocess, and the electrode switch 42 allows the user to select theelectrode type. In the illustrated embodiment, the electrode types maybe denoted as EXX10 and EXX18 to indicate that electrodes of varyingtensile strengths may be interchanged in the system. Similarly, the TIGbutton 48 initiates programming of a TIG welding process. The user mayselect a high frequency start method or a lift-arc start method usingthe start switch 50. In addition, the amperage supplied to the torch(e.g., welding gun) may be altered by rotating the amperage knob 44, andthe output amperage may be displayed on the display 46.

When a continuous wire process is selected, the MIG type switch 58enables the user to select a continuous wire welding process type, suchas, for example, a flux-cored arc welding (FCAW) process, a standard MIGwelding process, a regulated metal deposition (RMD) process, or a pulsedMIG welding process. For the selected process, the base material may beselected or input via the base material switch 54, and the wire diametermay be selected or input via the wire size switch 56. In addition, thegas selection button 60 may enable the user to select a shielding gasfor MIG welding processes, as described above. The selected gas may bedisplayed on the adjacent display chart 62. The trigger select button 66may enable or disable the ability of the user to change profiles byclicking the trigger on the torch or gun (e.g., the right and leftwelding guns 18 and 20).

In addition to the process settings configurable at the power sourceinterface 26, the left or right gun 18 or 20 (FIG. 1) may be selectedvia a side select button 172. By enabling the user to select the gun atthe power source, the user may not be required to walk back and forthbetween the power source and the wire feeder. This feature may beespecially useful where the power source is located at a considerabledistance from the wire feeder.

The illustrated embodiment of the power source interface 26 may alsoinclude a memory interface 174. The memory interface 174 may enablecommunication with a portable memory unit, such as a flash memory card,a pen drive, or an external hard drive, on which profile information maybe stored. In an exemplary embodiment, the memory interface 174 may haveone or more memory card slots 175 to receive portable memory cards(e.g., Secure Digital, CompactFlash, Memory Stick, xD, PCMCIA,SmartMedia, etc.). In another embodiment, the memory interface 174 mayinclude a port to which an external memory device may be coupled (e.g.,USB or mini-USB device, external hard drive, FireWire device, eSATAdrive, i.Link device, parallel SCSI device, etc.). A cover 176 mayprotect the memory interface 174 when not in use or when a memory cardis inserted in the card slot 175. The cover may be rotatably coupled tothe interface 26, e.g., via a hinge or pivot joints 177.

While the portable memory unit is coupled to the memory interface 174,information may be copied to and/or from the process control board (notshown). For example, by pressing a save button 178, the user may copythe settings from the power source interface 26 to the portable memorydevice. Similarly, the user may press a load button 180 to automaticallyimplement settings stored on the portable memory device. In anotherembodiment, the memory interface 174 may automatically load informationfrom the portable memory device upon coupling the memory device to theinterface 26 (e.g., plug-and-play). To indicate that the portable memorydevice is being accessed, a busy indicator 182 may be illuminated and/ormay flash on and off.

As described above, changes input to the torch system 10 (FIG. 1) viathe exemplary power source interface 26 may be automatically saved tothe profile which is selected at the time, or the changes may be savedmanually to the desired profile. The selected profile may be indicatedby the profile selectors 36 (e.g., via an integral or adjacent light).Profiles may be saved to the internal process control board and/or tothe portable memory unit. Each profile may correspond to one or moresets of operational parameters for the torch system 10, and theoperational parameters may be recalled at a later time upon reselectionof a given profile.

FIG. 7 illustrates another embodiment of the wire feeder interface 32for use with the exemplary power source interface 26 illustrated in FIG.6. The wire feeder interface 32 includes the left gun button 70 and theright gun button 72 to enable selection of the desired gun 18 or 20,respectively. As described above, the user may determine whether buttonson the wire feeder interface 32 are selected based on the position of atoggle switch, a lit label, or a similar indicator. The MIG process type(e.g., FCAW, standard, RMD, or pulse) selected at the power sourceindicator 26 (FIG. 6) may be indicated on the wire feeder interface 32by a continuous wire process indicator 184. For example, the selectedprocess type may be illuminated and/or may flash on and off to indicateits selection.

Within each MIG welding process, the voltage parameters and/or arclength may be set using the voltage knob 78, and the wire speed may beset using the wire feed speed knob 80. The selected voltage and wirefeed speed are displayed on the displays 82 and 84 adjacent the knobs 78and 80, respectively. As described above, the jog button 92 may bedepressed to thread wire through the welding gun 18 or 20 withoutactivating the weld process. The trigger hold button 88 may enable theuser to weld for an extended period of time without holding down thewelding gun trigger. The purge button 94 may be depressed to purgeshielding gas from the gun 18 or 20 without activating the weldingprocess.

In addition, the profile selection button 90 may enable the user toeasily switch between profiles without returning to the power/controlunit 12 (FIG. 1). Again, changes input via the exemplary wire feederinterface 32 may be stored to the selected profile for later recall. Anychanges made while a particular profile is selected may be automaticallysaved to that profile such that reselection of the profile returns thesettings to the last used settings for that profile. In anotherembodiment, changes may be manually saved to a desired profile after thesettings have been adjusted. For example, a save button (not shown) maybe activated, and the desired profile may be selected by depressing theprofile selection button 90. Selection of the save button again may thensave the settings to the selected profile. Furthermore, an indicator 186may signal to the operator that the portable memory unit is beingaccessed, similar to the busy indicator 182 (FIG. 6). The indicator 186may be illuminated when data is being transferred via the memoryinterface 174.

FIG. 8 is a flow chart illustrating an exemplary profile hierarchy 188that may be associated with the profile selectors 36 and 90 of theexemplary interfaces 26 and 32 illustrated in FIGS. 6-7. In theillustrated embodiments, the user may select a user/process profile 190by selecting one of the profile selectors 36 (FIG. 6) or depressing theprofile selection button 90 (FIG. 7) until the desired profile number isselected. As described above with respect to FIG. 5, default weldingparameters are automatically recalled the first time the profile 190 isselected. Any changes made while a given profile 190 is selected may beautomatically or manually saved such that they may be recalled at alater time by simply selecting that profile 190 again.

Within the profile 190, the user may select between a stick weldingprocess 192, a TIG welding process 194, a left gun process 196, or aright gun process 198. Additionally, a trigger select option 200 mayenable the profile 190 to be selected via the trigger on the torch orgun (e.g., the right and left welding guns 18 and 20). The stick weldingprocess 192 may include selection of either an EXX10 electrode 202 or anEXX18 electrode 204. For each electrode 202 and 204, amperage 206 and208 may be set, respectively. Likewise, in the TIG welding process, anamperage 210 may be input, and a high frequency start 212 or lift-arcstart 214 may be selected.

If the left gun process 196 is selected, a MIG process type 216 may bechosen. In addition, a voltage 218, a wire feed speed 220, a basematerial 222, a wire diameter 224, and a gas type 226 may be selected. Atrigger hold option 228, which allows the user to weld for an extendedperiod of time without holding down the welding gun trigger, may also beenabled or disabled. Similarly, if the right gun process 198 isselected, a MIG process type 230 may be chosen. A voltage 232, a wirefeed speed 234, a base material 236, a wire diameter 238, and a gas type240 may also be selected. In addition, a trigger hold option 242 may beenabled or disabled.

Furthermore, the profile 190 may be enabled to permit automatic profileselection through actuation of the left or right gun trigger. Enablingthe trigger select option 200 on two or more profiles allows the user toeasily switch between the profiles in which trigger select is activated.For example, if profiles 1 and 3 have trigger select enabled, the weldoperator may select between the two profiles by rapidly actuating theactive gun trigger. Subsequent actuation of the active gun trigger willswitch between profiles 1 and 3. If trigger select is enabled on morethan two profiles, trigger actuation will sequentially toggle throughthe profiles.

Other settings and processes may be specified based on the processesavailable on the given welding system 10. If multiple processes aredefined in the desired profile 190, the user may also press a button(e.g., the stick button 40, the TIG button 48, the side select button172, the left gun button 70, the right gun button 72, etc.) to recallthe operational parameters associated with the desired process 192, 194,196, or 198 in the desired profile 190. Selection of various processesbased on the process and/or the user may be programmed, as describedabove.

FIG. 9 illustrates an exemplary process control model 250 in accordancewith an embodiment of the present technique. Specifically, certaincomponents of the power/control unit 12 (FIG. 1) are illustrated. Theprocess control model 250 may include, for example, a microprocessor 252connected to a bus 254. Also connected to the bus 254 are a read-onlymemory (ROM) 256, a random access memory (RAM) 258, user inputinterfaces 260, and a display 262. The ROM 256 and the RAM 258 may beutilized to store programming information, such as, for example,programs to properly translate user input to desired output from thesystem 10. The microprocessor 252 may utilize the user input and storedprograms to command the power/control unit 12 to operate according tothe profiles. The user input interfaces 260 may include, for example,the interfaces 26 and 32 having profile selectors 36 and 90 and variousoperational control buttons, knobs, and switches described in FIGS. 2-4and 6-7. The display 262 may include the amperage display 46, thevoltage display 82, the wire feed speed display 84, the profile display38, the chart 62, etc.

Furthermore, the process control model 250 may include a non-volatilememory 264. The non-volatile memory 264 may include, for example, a harddrive, a flash memory drive, a tape drive, ROM, PROM, EPROM, EEPROM,etc. The non-volatile memory 264 may be integral with or separate fromthe ROM 256. User/process profiles may be stored on the non-volatilememory 264, for example, in a look-up table, and recalled upon selectionof the profile selectors 36 and 90. Default process settings may beinitially stored on the non-volatile memory 264. In one embodiment, theuser/process profiles may be updated automatically upon enteringsettings via the user input interface(s) 260. That is, as soon as a userchanges a setting, such as adjusting the amperage knob 44 or pressingthe left gun button 70, the active user/process profile may be updatedto reflect the change. In another embodiment, the user/process profilesmay be updated manually upon specific user input via the user inputinterface(s) 260. For example, after a user changes a setting, the usermay select to save the settings to a specific user/process profile. If adifferent user/process profile is selected, the previous settings forthat profile are recalled automatically from the non-volatile memory 264and displayed on the display(s) 262.

In some embodiments, the non-volatile memory 264 may be portable andeasily transferable to another system 10. For example, user/processprofiles may be copied from a first system 10 to a flash memory driveand transported to another system 10, where the user/process profilesare loaded for use. The process control model 250 may contain bothportable and fixed non-volatile memory 264, and transferring theuser/process profiles may consist of copying the profiles between theportable and the fixed non-volatile memory 264. For example, userdepression of the save button 178 (FIG. 6) may initiate copying of thedisplayed user/process profile from the fixed non-volatile memory 264 tothe portable non-volatile memory 264. Similarly, depression of the loadbutton 180 (FIG. 6) may initiate copying of the displayed user/processprofile from the portable non-volatile memory 264 to the fixednon-volatile memory 264.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A torch system comprising: a personalized interface, comprising: aplurality of selectors corresponding to a plurality of configurableprofiles, wherein each selector is configured to adjust operationalparameters of the torch system upon selection.
 2. The torch system ofclaim 1, wherein the plurality of selectors comprises a plurality ofbuttons each corresponding to a single configurable profile.
 3. Thetorch system of claim 1, wherein each selector enables recall of apersonalized configuration of the operational parameters withoutadjustment of various controls associated with the operationalparameters.
 4. The torch system of claim 1, wherein a single selectionof each selector is configured to recall the corresponding configurableprofile.
 5. The torch system of claim 1, wherein each selector isdisposed adjacent to a label area.
 6. The torch system of claim 5,wherein the label area comprises one or more reusable labeling surfaces.7. The torch system of claim 5, wherein the label area comprises one ormore displays.
 8. The torch system of claim 1, wherein a programmablecontroller comprises the personalized interface and is configured toautomatically save the operational parameters for the plurality ofconfigurable profiles.
 9. The torch system of claim 8, wherein aprogrammable controller comprises a flash memory reader/writerconfigured to copy the operational parameters for the plurality ofconfigurable profiles to/from a portable flash memory device.
 10. Thetorch system of claim 1, comprising a torch power unit, a welding gun, acutting torch, a wire feeder, a gas source, a power source, or acombination thereof.
 11. The torch system of claim 1, wherein theoperational parameters correspond to a stick welding process, a fluxcored arc welding process, a gas metal arc welding process, a shieldedmetal arc welding process, a gas tungsten arc welding process, a metalinert gas welding process, a pulsed metal inert gas welding process, atungsten inert gas welding process, a pulsed tungsten inert gas weldingprocess, a spot welding process, a resistance spot welding process, asubmerged arc welding process, a regulated metal deposition process, anair carbon arc cutting process, a plasma arc cutting process, or acombination thereof.
 12. The torch system of claim 1, wherein theoperational parameters comprise amperage, voltage, wire feed speed,electrode type, start method, base material, wire diameter, metal inertgas weld type, shielding gas, fixed torch, trigger hold, trigger select,or a combination thereof.
 13. A torch system, comprising: a programmablecontroller, comprising: a personalized user interface, wherein thepersonalized user interface comprises at least one quick selectorconfigured to recall operational parameters of a torch process.
 14. Thetorch system of claim 13, wherein the programmable controller comprisesat least one process user interface configured to enable input of theoperational parameters.
 15. The torch system of claim 14, wherein thepersonalized user interface enables the programmable controller torecall the operational parameters input to the process user interfacewithout adjusting settings on the process user interface.
 16. The torchsystem of claim 13, wherein the programmable controller comprises anon-volatile memory configured to store the operational parameters inassociation with one or more profiles, wherein the profiles areselectable via the quick selector.
 17. The torch system of claim 16,wherein the programmable controller is configured to automatically savethe operational parameters in association with the one or more profilesupon input of the operational parameters.
 18. The torch system of claim13, wherein the programmable controller comprises a flash memoryreader/writer configured to copy the operational parameters for theplurality of configurable profiles to/from a portable flash memorydevice.
 19. The torch system of claim 13, comprising a torch power unit,a welding gun, a cutting torch, a wire feeder, a gas source, a powersource, or a combination thereof.
 20. A torch system, comprising: one ormore tangible, machine-readable media comprising: code executable tosave operational parameters for a plurality of profiles automaticallyupon user selection of the operational parameters for each profile; orcode executable to recall the operational parameters for each profile toconfigure the torch system based on a one-click user selection of eachprofile; or a combination thereof.
 21. The torch system of claim 20,wherein the code is executable to save and/or recall the operationalparameters for a plurality of different torch processes for eachprofile.
 22. The torch system of claim 20, comprising a non-volatilememory configured to store the operational parameters associated withthe profiles.
 23. The torch system of claim 20, wherein a programmablecontroller comprises the one or more tangible, machine-readable mediaand is configured to receive the operational parameters via at least oneuser interface.
 24. A method, comprising: automatically saving a userprofile to a profile selector based on one or more selections ofoperational parameters of a torch system via controls separate from theprofile selector.
 25. The method of claim 24, comprising recalling theoperational parameters upon selection of the user profile via theprofile selector.
 26. A method, comprising: saving operationalparameters of a torch system to a desired profile upon user selection ofa save option and/or the desired profile; and recalling the operationalparameters upon a one-step selection of the desired profile.
 27. Themethod of claim 26, wherein user selection of the desired profilecomprises depressing and holding a selector associated with the profile.28. A torch system, comprising: a personalized interface, comprising: aplurality of customizable profiles each having operational parametersfor the torch system; and a desired customizable profile is selectablewithout scrolling through a list of the plurality of customizableprofiles.
 29. The torch system of claim 28, wherein the desiredcustomizable profile is selectable by a single depression of acorresponding button.